Installation. PRXB For HINO Trucks MANUAL. Hino Trucks with J05D-TA Engine and Aisin Automatic Transmission EXHAUST BRAKE.

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1 Installation MANUAL ELECTRICAL ONLY PRXB For HINO Trucks EXHAUST BRAKE PRXB Application: Hino Trucks with J05D-TA Engine and Aisin Automatic Transmission

2 Hino Trucks With Aisin Transmission Addendum Hino trucks equipped with Aisin Automatic transmissions require an additional electronic control module installed to deactivate the exhaust brake when the torque converter is not in lock up. When installed correctly the control module will turn off the exhaust brake at 30 MPH, 50 KM/HR. NOTE: This manual covers the electrical installation procedure. For the exhaust brake and air compressor installation procedure follow the additional manual supplied with the exhaust brake kit. Electrical Installation Note: Disconnect the batteries before removing the conectors from the ECU. Locate the wiring schematic on Page 6 and the ECU rack drawing (RIGHT): ABS ECU ENGINE ECU (U2) 1 Remove the fuse panel cover on the passengers side of the dash. Passenger side fuse panel 2 Above the fuse panel, locate the three threaded holes in the fuse panel support bracket. 3 Using the 3 capscrews provided, secure the control unit mounting bracket to the fuse panel support bracket. Locate the BLACK ground wire of the Pacbrake main electrical harness, install the BLACK wire with eye terminal under the head of one of the capscrews. I N S T A L L A T I O N M A N U A L - L P G.

3 4 Using the 2 capscrews provided secure the control unit to the mounting bracket as shown. Install the two electrical harness connectors into the control box. 5 Feed the 2 RED 14 gage wires into the engine compartment through the firewall grommet in the upper passengers side of the firewall. Using the loom and tie-straps provided secure the wiring harness and apply electrical tape to the grommet to provide a seal. 6 Mount the relay receptacles to one of the ECU mounting bracket capscrews. A replacement capscrew is provided. All vehicles require two relays, one for throttle control and the other is for ABS (Anti-lock Brake System). 7 At the engine ECU, locate the connector shown in the electrical schematic. Remove the connector from the ECU. The connector locking device needs to be released before the Pacbrake terminals can be installed. Insert a small screwdriver into the square hole that exists in each side of the connector. Push against the tab and repeat on the opposite side. The terminal locking device should raise by 1 to 2mm but is not removable. This will allow the terminals to be installed. Insert the GREEN Pacbrake wire into port B15, the BLACK wire into Port B24 and the BLUE wire into port B2. Once all three Pacbrake wires are installed, push the locking device down to lock the terminals in place. An audible click should be heard to ensure the locking device is locked. Install the connector back into the ECU. I N S T A L L A T I O N M A N U A L - L P G.

4 8 At the fuse panel, locate the air dryer fuse location. It should be an ignition source and available to accept the fuse tap provided. The fuse tap must be installed in a certain manner for the fuse to protect the system. Using a test light, determine which terminal in the fuse panel is the ignition power input. The fuse tap terminal opposite the wiring harness side must be installed into the power source terminal for the fuse to be effective. If no empty ignition power locations are available in the fuse panel, choose an existing ignition circuit. Remove the existing fuse and install the fuse tap. Install the original fuse in the lower position of the fuse tap. 9 The ABS ECU has a Pacbrake disable circuit to turn the exhaust brake off in the event of wheel lock-up and, therefore, must be connected to the ABS ECU. Locate the ABS ECU in the ECU rack. Remove the 15 pin connector from the ABS ECU, pull the VIOLET lock tab out allowing the terminal on the YELLOW wire to be installed in port 12 of the connector. Then push the VIOLET lock tab in to secure the terminal. Install the connector back into the ABS ECU. Consult the electrical schematic on Page 6 for the ABS connector numbering sequence. 10 Route the VIOLET and RED twisted pair of wires to the transmission connector. (As shown by the arrows) 11 Connect the VIOLET wire of the twisted pair to the VIOLET wire of the transmission connector. This connection must be soldered, and covered with the heat shrink provided. Connect the RED wire of the twisted pair to the PINK wire of the transmission connector. This connection must be soldered, and covered with the heat shrink provided. Secure the wires with the tie straps provided. I N S T A L L A T I O N M A N U A L - L P G.

5 12 Dash Switch Installation Provided in the dash are spare cavities for the exhaust brake s dash switch. Choose a location that is convenient for the driver to access and remove the blank plate. Route the leg of the harness with the BROWN and GREEN wires behind the dash and feed them to the switch opening. Connect the wires to the switch as shown in the wiring schematic on Page 6 and insert the switch into the dash. Provided is a decal to identify the switch. Peel the paper off the back of the decal and apply either above or below the switch. Secure the harness with the tie-straps provided. 13 Feed the two remaining GRAY and GREEN wires through the firewall grommet under the floormat, near the accelerator pedal. These will connect to the air compressor installed in the next step. Seal the grommet to provide a water tight seal. Secure wires with the straps provided. 14 Route the GRAY, GREEN and the 2 RED 14 gage wires of the Pacbrake harness to the compressor assembly. The longer RED wire goes to the batteries on the drivers side. Connect the GRAY wire to the pressure switch, the GREEN wire to the solenoid and the short RED to the compressor. The terminals are filled with dielectric compound to prevent corrosion. Cover the connectors with electrical tape. Using the loom and tie-straps provided protect and secure the harness. 15 Route the remaining 14 gage RED wire from the firewall boot to the battery box on the drivers side. Supplied in the kit is an inline 30 amp fuse. Connect the inline fuse to the RED wire. The terminal is filled with dielectric compound to prevent corrosion. Cover the connector with electrical tape. Connect the eye terminal to the positive battery lead with the eye terminal placed under the larger terminal. Torque nut to /- 2.2 lbs.ft. Cover the entire RED wire with loom and secure with tie-straps provided. Reconnect the batteries. Refer to the main installation manual for compressor and exhaust brake installation instructions. I N S T A L L A T I O N M A N U A L - L P G. 5

6 Engine ECU Terminal No. E31 E30 E29 E28 E27 E26 D35 D34 D33 D32 D31 D30 D29 D28 C32 C31 C30 C29 C28 B35 B34 B33 B32 B31 B30 B29 B28 A34 A33 A32 A31 A30 A29 A28 E25 E24 E23 E22 E21 E20 E19 E18 D27 D26 D25 D24 D23 D22 D21 D20 D19 D18 D17 C27 C26 C25 C24 C23 C22 C21 C20 C19 C18 B27 B26 B25 B24 B23 B22 B21 B20 A27 A26 A25 A24 A23 A22 A21 A20 A19 A18 E17 E16 E15 E14 E13 E12 E11 E10 E9 E8 E7 E6 E5 E4 E3 E2 E1 D16 D15 D14 D13 D12 D11 D10 D9 D8 D7 C17 C16 C15 C14 C13 C12 C11 C10 C9 C8 B19 B18 B17 B16 B15 B14 B13 B12 B11 B10 B9 B8 A17 A16 A15 A14 A13 A12 A11 A10 A9 A8 D6 D5 D4 D3 D2 D1 C7 C6 C5 C4 C3 C2 C1 B7 B6 B5 B4 B3 B2 B1 A7 A6 A5 A4 A3 A2 A1 BLACK connect to B24 BLUE connect to B2 3 amp fuse fuse tap 3 CONNECT TO GOOD CHASSIS GROUND BROWN BLACK Pacbrake On/Off Switch GREEN connect to B15 RED BLACK ABS Disable Relay 87A Throttle Switch Relay A BROWN Pacbrake Solenoid GREEN YELLOW GREEN BROWN GREEN Pacbrake Control Unit Solder Connection Positive Battery Terminal 30 amp fuse RED BLACK VIOLET RED Solder Connection VIOLET Aisin Transmission PINK EXISTING HINO HARNESS YELLOW RED (14 GAGE) GRAY BLUE BLUE Pressure Switch ABS CONNECTOR (Back View Of Shown) Pacbrake compressor NOTE: Aisin Transmission, view shown is looking at the harness side, ECU is mounted in vehicle with the connector lock tab facing down NOTE: Relays MUST be Diode Protected I N S T A L L A T I O N M A N U A L - L P G. 6